ProCore® 648 Aerator

Parts needed for this procedure:

1. Remove the 8 lug nuts securing the rear of the aerator to the packaging.

2. Mount a wheel assembly onto each rear wheel hub (Figure 3).

   

   Figure 3

   1. Wheel assembly
   2. Lug nut

3. Install the lug nuts (Figure 3) and tighten them to 61 to 75 N∙m (45 to 55 ft-lb).

4. Deflate all tires to 83 kPa (12 psi).

Parts needed for this procedure:

1. Carefully rotate the handle to the front of the machine. Use caution not to damage the cables.

2. Insert the handle mounting studs into the holes in the fork (Figure 4).

   

   Figure 4

   1. Handle
   2. Fork
   3. Locknut
   4. Cable guide

3. Secure handle studs to fork with 3 locknuts (1/2 inch) (Figure 4)

4. Insert the cable guide around the cables.

5. Mount the cable guide to the top of the fork with 2 bolts (5/16 x 1/2 inch) (Figure 4).

Parts needed for this procedure:

1. Unlatch and open the battery compartment cover.

2. Remove the battery from the battery compartment (Figure 5).

   

   Figure 5

   1. Battery compartment

3. Clean the top of the battery and remove the vent caps.

4. Carefully fill each cell with electrolyte until the plates are covered with about 6 mm (1/4 inch) of fluid.

   Use only electrolyte (1.265 specific gravity) to fill the battery initially.

   Important: Do not add electrolyte while the battery is in the machine. You could spill it, causing corrosion.

   Danger

   Battery electrolyte contains sulfuric acid which is fatal if consumed and causes severe burns.

   • Do not drink electrolyte and avoid contact with skin, eyes, or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

   • Fill the battery where clean water is always available for flushing the skin.

5. Allow approximately 20 to 30 minutes to allow all trapped gas to escape from the plates. Refill as necessary to bring the electrolyte to within about 6 mm (1/4 inch) of the bottom of the fill well.

6. Connect a 3 to 4 A battery charger to the battery posts. Charge the battery at a rate of 3 to 4 A until the specific gravity is 1.250 or higher and the temperature is at least 16 degrees C (60 degrees F ) with all cells gassing freely.

   Warning

   Charging the battery produces gasses that can explode.

   Never smoke near the battery and keep sparks and flames away from it.

7. When the battery is charged, disconnect the charger from the electrical outlet and battery posts.

   Note: After the battery has been activated, add only distilled water to replace normal loss, although maintenance-free batteries should not require water under normal operating conditions.

8. Insert the battery into the tray in the battery compartment (Figure 6) Position the battery so the terminals are to the outside.

   Warning

   Battery terminals or metal tools could short against metal machine components causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

   • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

   • Do not allow metal tools to short between the battery terminals and metal parts of the machine.

9. Secure the battery to the compartment base with a battery rod, 2 hold down rods, 2 flat washers, and 2 wing nuts (Figure 6).

   

   Figure 6

   1. Battery tray
   2. Battery hold down
   3. Hold down rod
   4. Positive terminal (+)
   5. Negative terminal (–)

10. First, secure the positive cable (red) to the positive (+) battery terminal with a carriage bolt and nut (Figure 6), then the negative cable (black) to the negative (–) terminal of the battery with a carriage bolt and nut (Figure 6). Slide the rubber boot over the positive terminal to prevent a possible short from occurring.

    Important: Make sure there is clearance between the battery cables and the speed selector lever. Verify that the speed selector lever does not come within 1 inch (2.5 cm) of either battery cable when it is moved through its entire range of motion. Do not wire tie or tape the negative and positive battery cables together.

    Warning

    Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

    • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

    • Always connect the positive (red) battery cable before connecting the negative (black) cable.

11. Close and latch the battery compartment cover.

Parts needed for this procedure:

If you are setting up this machine for use in the European Union (CE), secure the rear hood as follows to comply with CE regulations.

1. Install a latch lock over the left and right side hood latches with a tap bolt (2 total) (Figure 7).

   

   Figure 7

   1. Tap bolt
   2. Latch lock
   3. Internal lock washer (inside of hood)
   4. Hood

2. Using a pliers or adjustable wrench, thread an internal lock washer onto each bolt (1 to 2 threads) to secure the bolts (Figure 7).

Parts needed for this procedure:

If you are setting up this machine to be compliant with CE, secure the belt cover as follows.

1. Locate the hole in the belt cover next to the latch lever (Figure 8 and Figure 9).

   

   Figure 8

   1. Belt cover
   2. Latch lever

2. Using the hole in the belt cover, install the lanyard assembly with a pop rivet (Figure 9).

   

   Figure 9

   1. Belt cover hole
   2. Lanyard
   3. Pop rivet

3. Thread the bolt into the latch lever (Figure 10).

Figure 10

1. Bolt
2. Latch lever
3. Nut

Parts needed for this procedure:

After all the necessary CE requirements are met, apply the CE decal and the production year decal to the fork leg (Figure 11).

Figure 11

1. Apply the decals here.

A wide selection of tine holders, turf guards, and tines are available for the aerator. Install the setup appropriate for your application as described in Installing Tine Holders, Turf Guards, and Tines.

To move forward, move the traction lever forward. To move rearward, move the traction lever rearward (Figure 13).

The farther you move the traction lever, the faster the aerator will move.

To stop, release the traction lever.

To engage the parking brake, move the lever toward the engine. To disengage the parking brake, move the lever forward (Figure 13).

Always engage the parking brake when you stop the aerator or leave it unattended.

Jog the traction lever forward and reverse to disengage the parking brake.

The oil pressure warning light (Figure 13) glows when the oil pressure in the engine drops below a safe level. If low oil pressure ever occurs, shut off the engine and determine the cause. Repair the damage before starting the engine again.

Raise—Press the top of the switch (Figure 13) to raise the coring head and disengage the coring head. The engine must be running to generate lift pressure. If the coring head is below the transport height, refer to Resetting the System Control Circuit.

Lower/Engage—Press the bottom of the switch (Figure 13) to lower and engage the coring head. The traction lever must be in the forward position to activate the switch.

To lower the coring head without engaging it, turn the ignition key to the Run position (without the engine running), move the traction lever to the forward position, and press the bottom of the switch.

The ignition switch (Figure 14), which is used to start and shut off the engine, has 3 positions: OFF, RUN, and START. Rotate key clockwise to the START position to engage the starter motor. When the engine starts, release the key and it will move automatically to the ON position. To shut off the engine, rotate the key counterclockwise to the OFF position.

Figure 14

1. Ignition
2. Aerator spacing lever
3. Throttle
4. Choke
5. Hour meter/tachometer
6. Manual ground follow
7. System reset

Move aerator spacing lever (Figure 14) to desired hole spacing or to T for transport.

The throttle (Figure 14) is used to operate engine at various speeds. Moving throttle forward increases engine speed (Fast position); backward decreases engine speed (Slow position). The throttle regulates the speed of the coring head and controls the ground speed of the machine.

When the engine is off, the hour meter/tachometer (Figure 14) displays the number of hours of operation that have been logged on the machine. When the engine is running, it displays the speed of the engine in revolutions per minute (RPM).

After the first 50 hours of operation and then after every 100 hours (e.g. 150, 250, 350, etc.) the screen displays “CHG OIL” to remind you to change the engine oil. After every 100 hours (e.g. 100, 200, 300, etc.), the screen displays “SVC” to remind you to perform the other maintenance procedures based on a 100, 200, or 500 hour schedule. These reminders come on starting 3 hours prior to the service interval time and flash at regular intervals for 6 hours.

To start a cold engine, close the carburetor choke by moving choke control (Figure 14) fully forward. After the engine starts, regulate the choke to keep the engine running smoothly. As soon as possible, open the choke by pulling it backward.

Rotate the switch to the down position to turn off the TrueCore feature (Figure 14) Remove the bolt to access the manual ground switch.

Press the system reset switch (Figure 14) to raise the coring head if the system becomes disabled (e.g., engine out of fuel, etc.)

Move the lever to the desired depth of aeration (Figure 15)

Figure 15

1. Aeration depth lever
2. Depth decal

A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of all approved attachments and accessories.

Refer to the following table for the tine head, tine holder, and tine configurations:

• Fuel tank capacity: 26.5 L (7 US gallons)

• Recommended Fuel:

  • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

  • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol ). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

  • Do not use fuel containing methanol.

  • Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

  • Do not add oil to fuel.

Important: Do not use fuel additives other than a fuel stabilizer/conditioner. Do not use fuel stabilizers with an alcohol base such as ethanol, methanol, or isopropanol.

Important: Do not use methanol, gasoline containing methanol, or gasohol containing more than 10% ethanol because the fuel system could be damaged. Do not mix oil with fuel.

The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started.

Crankcase capacity is approximately 1.9 L (2.0 US qt) with the filter.

Use high-quality engine oil as described in Changing the Engine Oil and Filter.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill. If the oil level is between the Full and Add marks, no oil addition is required.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Clean around the oil dipstick (Figure 17) so dirt cannot fall into the filler hole and damage the engine.

   

   Figure 17

   1. Dipstick
   2. Filler tube
   3. Metal end of the dipstick

3. Remove the dipstick, wipe it clean, and install until it is fully seated (Figure 17).

4. Remove the dipstick and check the oil level on the dipstick.

   The oil level should be up to the Full mark on the metal end of the dipstick (Figure 17).

5. If the oil level is below the Full mark, remove the filler tube cap (Figure 17) and add oil until the level reaches the Full mark on the dipstick. Do not overfill.

   Important: Do not overfill the crankcase with oil because this may cause engine damage. Do not run the engine with oil below the low mark because the engine may be damaged as a result.

6. Install the filler tube cap and dipstick.

The hydraulic reservoir is filled at the factory with approximately 6.6 L (1.75 US gallons) of high-quality hydraulic fluid. Check the level of the hydraulic fluid before the engine is first started and daily thereafter.

Hydraulic fluid-type specification:

Alternative fluids: If the specified fluid is not available, other universal tractor hydraulic fluids (UTHF) may be used, but they must be only conventional, petroleum-based products, not synthetics or biodegradable fluids. The specifications must fall within the listed range for all of the following material properties and the fluid should meet listed industry standards. Check with your fluid supplier to see if the fluid meets these specifications.

Note: Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic fluid is available in 20 ml (2/3 fl oz) bottles. One bottle is sufficient for 15 to 22 L (4 to 6 US gallons) of hydraulic fluid. Order part number 44-2500 from your authorized Toro distributor.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Unlatch and remove the belt cover (Figure 18).

   

   Figure 18

   1. Belt cover
   2. Cover latch

3. Clean the area around the filler neck and the cap of the hydraulic tank (Figure 19). Remove the cap from the filler neck.

   

   Figure 19

   1. Hydraulic-tank cap

4. Remove the dipstick from the filler neck and wipe it with a clean rag. Insert the dipstick into the filler neck; then remove it and check the level of the fluid. The fluid level should be up to the mark on the dipstick (Figure 20).

   

   Figure 20

   1. Dipstick
   2. Full mark

5. If the level is low, add the appropriate fluid to raise the level to the full mark.

6. Install the dipstick and cap onto the filler neck.

Before each use, check and clean the engine screen. Remove any buildup of grass, dirt, or other debris from the engine air intake screen.

1. Start the engine.

2. Disengage the parking brake.

3. Look in the direction of your planned path to ensure that it is clear.

4. Move the traction lever down to drive the machine forward.

   Walk in a forward direction while operating the machine, do not walk and face backwards when operating the machine.

5. Engage the PTO and lower the coring head.

6. Disengage the PTO and raise the coring head.

7. To stop the machine, release the traction lever.

Install the service latches before performing service on the coring head or when storing the machine for more than a couple of days.

1. Raise the coring head.

2. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

3. Remove the clip ring securing the service latch in the storage position (Figure 21).

   

   Figure 21

   1. Service latch in (lowered) storage position

4. Pivot the service latch rearward and insert it onto the coring head pin (Figure 22). Secure it with the clip ring.

   

   Figure 22

   1. Service latch in (raised) locked position

A wide selection of tine holders, turf guards, and tines are available for the aerator. Choose the required components per the accessory chart in Attachments and Accessories.

1. Raise the coring head and lock it in position with the service latch.

2. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

3. Mount a tine holder to each tine arm with 3 bolts (1/2 x 1-1/4 inches) (Figure 23). Torque the bolts to 101.6 N∙m (75 ft-lb).

   Note: The bolts are provided in the tine holder kits.

   

   Figure 23

   1. Tine arm
   2. Tine holder

4. Loosely install the turf guards to the turf guard brackets with 4 turf guard clamps and 12 flange nuts (Figure 24). Do not tighten the fasteners.

   Note: The turf guard clamps and flange nuts are shipped secured to the turf guard brackets (Figure 24).

   

   Figure 24

   1. Turf guard
   2. Turf guard clamp

5. Loosely install a tine clamp to each tine holder with 4 bolts (3/8 x 1-1/2 inches) (Figure 25). Do not tighten the bolts.

   

   Figure 25

   1. Tine clamp
   2. Tine

6. Install tines into the #2 and #5 tine holders (Figure 26) Tighten the bolts.

   

   Figure 26

   1. Number 5 tine holder
   2. Number 2 tine holder

7. Check that the tines line up with the center of the gaps in the turf guards (Figure 27). Adjust the turf guards as required and tighten the nuts.

   

   Figure 27

   1. Gaps in the turf guards

8. Install the remaining tines into the #1, 3, 4, and 6 tine holders. Torque all tine holder bolts to 40.6 N∙m (30 ft-lb)

Refer to Installing Tine Holders, Turf Guards, and Tines for illustrations.

1. Raise the coring head and lock it in position with the service latch.

2. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

3. Loosen the tine holder retaining bolts and remove the old tines.

4. Insert the new tines into the tine holder.

5. Tighten the bolts to the recommended torque level.

6. Repeat this procedure on the remaining arms.

To set the coring depth of the aerator, proceed as follows:

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Select the preferred tine for your application.

3. Lay the tine on the tine depth decal (Figure 28) with 1 end lined up with the desired depth of aeration (refer to the tine overlay on the decal).

   

   Figure 28

   1. Aeration depth lever
   2. Overlay on decal

4. Determine which letter setting the other end of the tine lines up with and set the depth control lever to the corresponding letter setting.

Note: As the tine wears, you may be able to reset the depth setting to account for that wear. For instance, if your new tine depth setting has you in the G setting, you can reset to the H setting after 6 mm (1/4 inch) of tine wear.

The only time the manual depth setting spacers are required is if the TrueCore^® ground following system is not functioning due to damage to the feedback system (turf guards, tie rod, and actuator assembly) or if maximum coring depth is required.`

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Remove the lynch pin retaining the spacers and depth pins (Figure 29).

   

   Figure 29

   1. Lynch pin
   2. Spacers and depth pin

3. Position the spacers above or below the bracket to attain the desired coring depth.

   • Thick spacers equate to 19 mm (3/4 inch) increments.

   • Thin spacer equates to 9.5 mm (3/8 inch) depth increment.

   • With all spacers on the top side, the depth setting is 10.7 cm (4-1/4 inches).

4. Remove the locking bolt and nut from the selector switch (Figure 30).

   

   Figure 30

   1. Manual ground following selector switch
   2. Bolt and nut

5. Rotate the switch to the down position to turn off True Core feature.

6. Install the locking bolt and nut to ensure that the setting is not accidentally changed.

Important: Never tow the aerator faster than 1.6 km/h (1 mph) because hydraulic component damage may occur.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Locate the bypass valve between the engine and hydrostatic pump (Figure 31).

3. Using a 5/8 inch wrench, rotate the bypass valve counterclockwise 1 turn. This allows the hydraulic fluid to bypass the pump enabling the wheels to turn (Figure 31).

   

   Figure 31

   1. Bypass valve

   Important: Do not rotate the bypass valve more than 1 turn. This prevents the valve from coming out of the body and causing fluid to run out.

   Important: Do not push/pull the aerator more than 100 ft or faster than 0.6 km/h (1 mph) because hydraulic component damage may occur.

4. Disengage the parking brake before pushing/pulling the machine.

   Important: Do not operate the engine with the bypass valve open for more than 10 to 15 seconds.

5. To operate the aerator again, rotate the bypass valve clockwise 1 turn (Figure 31).

   Note: Do not overtighten the bypass valve.

   Note: The aerator will not drive unless the bypass valve is turned closed. Do not try to operate traction system with the bypass valve open.

If the coring head is ever left in the aerating position (run out of fuel, forget to install service latch for storage, mechanical failure of engine/pump, etc.) the electrical system that controls the hydraulic solenoid coils and the electric clutch is disabled to prevent unintended movement of the coring head without the deliberate action of resetting the system.

To reset the system after engine is started, press the rocker switch (Figure 32) to raise the coring head and reset the electrical control circuit.

Figure 32

1. Circuit reset switch

In the event that the engine fails or cannot be restarted with the coring head lowered and tines are engaged in the soil, proceed as follows:

1. Remove the tine holders from the stomper arms.

2. Open the bypass valve 1 turn.

3. Pull/push the aerator to a nearby location to continue service or load onto a trailer.

Important: Do not pull/push aerator for more than 100 feet and no faster than 1.6 km/h (1 mph) because hydraulic damage may occur.

There are tie downs located at the front and rear sides of the machine (Figure 33, Figure 34, and Figure 35).

Note: Use properly-rated DOT-approved straps to tie down the machine.

Figure 33

1. Tie down

Figure 34

1. Tie down

Figure 35

1. Tie down

• Use full-width ramps for loading the machine onto a trailer or truck.

• Tie the machine down securely.

Important: Do not use the Hydroject trailer/tote to trailer this aerator.

Trailer Recommendations

Use the line marker to align aeration rows (Figure 36).

Figure 36

1. Line marker (storage position)
2. Line marker (alignment position)

The machine is designed to transfer weight from the traction unit to the coring head to help maintain hole depth in various soil structures. However, if the soil structure is firm enough to not allow full aeration depth some additional weight transfer may be required. To increase the down pressure of the weight transfer springs, proceed as follows:

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Loosen the carriage bolt nuts securing the spring brackets to the coring head (Figure 37). Do not remove them.

   

   Figure 37

   1. Weight transfer springs
   2. Spring plate

3. Insert a 1/2 inch ratchet or breaker bar into the square hole in the spring plate (Figure 38).

   

   Figure 38

   1. Square hole in bracket
   2. Rear carriage bolt

4. Hold the ratchet or breaker bar to relieve the tension on the spring plate and remove the rear carriage bolt.

5. Rotate the spring plate until it is aligned with the other hole, insert the carriage bolt, and tighten the nuts.

   Note: Rotating the spring plates upward will increase the weight transfer.

With the increased weight transfer, it is possible to aerate firm enough ground that the weight transfer begins to lift the rear 2 tires off the ground. This may lead to irregular hole spacing.

If this occurs, an additional weight plate can be added to the rear frame axle tube. Each cast weight adds 28.5 kg (63 lb) to the machine. Up to 2 plates can be added. Refer to the Parts Catalog for these part numbers.

The Aerator Control Module is a potted electronic device produced in a 1-size-fits-all configuration. The module uses solid-state and mechanical components to monitor and control electrical features required for safe product operation.

Figure 39

1. Aerator control module

The module monitors inputs including head low, head high, transport, aerate, and ground following. The module is divided into inputs and outputs. Inputs and outputs are identified by green LED indicators mounted on the printed circuit board. Power is identified by a red LED indicator.

The start circuit input is energized by 12 VDC. All other inputs are energized when the circuit is closed to ground. Each input has an LED that is illuminated when the specific circuit is energized. Use the input LED’s for switch and input circuit troubleshooting.

Output circuits are energized by an appropriate set of input conditions. The 3 outputs include SVL, SVR, and SVQ. Output LED’s monitor relay conditions indicating the presence of voltage at 1 of 3 specific output terminals.

Output circuits do not determine output device integrity, so electrical troubleshooting includes output LED inspection and conventional device and wire harness integrity testing. Measure disconnected component impedance, impedance through wire harness (disconnect at ACM), or by temporarily test energizing the specific component.

The ACM does not connect to an external computer or handheld device, cannot be reprogrammed, and does not record intermittent fault troubleshooting data.

The decal on the ACM includes only symbols. 3 LED output symbols are shown in the output box. All other LEDs are inputs. The chart below identifies the symbols.

Figure 40

1. On/off
2. Output
3. Solenoid valve lower
4. Solenoid valve raise
5. Solenoid valve quick
6. Input
7. Head low
8. Head high
9. Transport (1)
10. Aerate (4)
11. Ground following
12. OK to lower

Here are the logical troubleshooting steps for the ACM device.

1. Determine the output fault you are trying to resolve.

2. Move the key switch to the On position and ensure the red power LED is illuminated.

3. Move all input switches to ensure that all LEDs change state.

4. Position input devices at the appropriate position to achieve the appropriate output.

5. If specific output LED is illuminated without appropriate output function, check output harness, connections, and component. Repair as required.

6. If specific output LED is not illuminated, check both fuses.

7. If specific output LED is not illuminated and inputs are in appropriate condition, install new ACM and determine if fault disappears.

Important: The fasteners on the covers of this machine are designed to remain on the cover after removal. Loosen all of the fasteners on each cover a few turns so that the cover is loose but still attached, then go back and loosen them until the cover comes free. This will prevent you from accidentally stripping the bolts free of the retainers.